Low Profile, High Efficiency Blower Assembly

ABSTRACT

An air distribution blower housing for a low profile air handler such as a residential furnace is designed with a volute-shaped outer wall that has an exponentially increasing expansion angle in the direction of air flow through the blower housing for at least a portion of the volute-shaped outer wall length. This results in the blower housing having an enlarged air outlet opening that slows down and spreads out the air flow from the blower housing over a greater area of the furnace heat exchanger. The blower housing thereby enables less air pressure drop through the heat exchanger, which increases the efficiency of the blower motor operation. The design of the blower housing also efficiently turns the velocity head of the air flow through the housing to usable static air pressure at the housing air outlet.

RELATED APPLICATIONS

This patent application claims the benefit of the filing date ofprovisional patent application No. 61/372,613, which was filed on Aug.11, 2010.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention pertains to a low profile furnace that comprises acompact enclosure for residential use and an air distribution blowerhousing that is designed with an outer wall having an exponentiallyincreasing expansion angle and an enlarged air outlet opening. Theenlarged outlet opening slows down and spreads out the air flow from theblower housing over a greater area of the heat exchanger of a lowprofile furnace. Thus, the blower housing enables less air pressure dropthrough the heat exchangers, which increases the efficiency of theblower operation. The design of the blower housing also efficientlyturns the velocity head of the air flow to usable static pressure at thehousing air outlet. The enlarged air outlet opening of the blowerhousing is achieved without increasing the exterior dimensions of theblower housing whereby the blower housing is used in a compact enclosurefor residential use. This is accomplished by utilizing a unique designvolute outer wall of the blower housing that has a unique exponentiallyincreasing expansion angle in the direction of air flow through theblower housing and compact relative positioning of the blower housingand heat exchangers in the furnace enclosure. The blower is specificallydesigned to enable a large impeller to operate in a low profile blowerhousing at higher efficiencies.

2. Description of Related Art

High efficiency residential natural gas powered furnaces are becomingmore and more common. A furnace of this type is defined in the industryas a 90+ AFUE (Annul Fuel Utilization Efficiency) furnace. A 90+ furnaceconverts more than 90% of the fuel supplied to the furnace to heat, withthe remainder being lost through the chimney or exhaust flue. Theseparticular types of furnaces employ a primary heat exchanger found inmost any type of furnace, plus an additional secondary heat exchanger.The secondary heat exchanger increases the capacity of the furnace toconvert the heat of the gas combustion to the distribution air flow fromthe furnace, and thereby defines the furnace as a high efficiencyfurnace.

The typical construction of a high efficiency furnace 10 is shown inFIG. 1. The furnace 10 has an external housing enclosure 12 with aninterior volume 14. Several portions of the side walls of the furnaceenclosure 12 shown in FIG. 1 have been removed to illustrate theinterior components of the furnace. The dimensions of the furnaceenclosure 12 are determined to contain all of the component parts of thefurnace in the enclosure 12, without the enclosure occupying asignificant area in the residence in which the furnace is installed. Incontrast, commercial furnaces are typically mounted on the roof of abuilding or at some other location outside the building where there areno size restraints. Because commercial furnaces with their largecapacity are located outside the structures they serve, there is no needto position the component parts of the furnace relative to each other tominimize the size of the furnace enclosure as there is in residentialfurnaces.

An air inlet opening is typically provided in a side wall or in thebottom of the furnace enclosure. The air inlet opening can be covered byan air filter that allows ambient air in the environment surrounding theenclosure 12 to easily pass through the opening and enter the enclosureinterior 14. Alternatively and more frequently, the air inlet opening ofthe furnace enclosure communicates with a cold air return duct system ofthe residence. The cold air return duct system channels ambient air fromthroughout the residence to the furnace enclosure.

The furnace enclosure also has an air distribution outlet opening 18.The outlet opening communicates with an air distribution conduit or ductsystem of the residence in which the furnace is installed. In FIG. 1,the air distribution outlet opening is located at the top of theenclosure 12. The air heated by the high efficiency furnace 10 isdischarged to the air distribution conduit system (not shown) throughthe distribution air outlet opening 18.

In the typical construction of a high efficiency furnace represented inFIG. 1, a primary heat exchanger 22 is located at the top of theenclosure 12 adjacent the distribution air outlet opening 18. Asecondary heat exchanger 24 that qualifies the furnace as a highefficiency furnace is located directly below the primary heat exchanger22.

An air distribution blower 26 that draws ambient air into the furnaceenclosure 12 is positioned just below the secondary heat exchanger 24. Amotor (not shown) of the blower rotates a fan wheel 28 in the interiorof the blower in a clockwise direction as viewed in FIG. 1. Thisrotation of the fan wheel 28 draws the ambient air into the blower 26 asrepresented by the arrow labeled (AIR FLOW) in FIG. 1, and pushes theambient air out of the blower through the secondary heat exchanger 24,then through the primary heat exchanger 22, and then out of theenclosure through the air distribution outlet opening 18.

A typical blower 26 includes a blower housing that contains the fanwheel 28. The typical blower housing includes an exterior or outer wall32 having a scroll or volute configuration. The outer wall 32 spiralsaround the fan wheel 28 in the direction of fan wheel rotation. A pairof side walls 34, only one of which is shown in FIG. 1, cover overopposite sides of the volute outer wall 32 and enclose the interior ofthe blower 26.

As shown in FIG. 1, the typical volute outer wall 32 of the blowerhousing has a constant expansion angle as it extends in the fan wheelrotation direction around the fan wheel. What is meant by expansionangle is the angle at which the outer wall expands in the direction offan wheel rotation from any point on the exterior of the outer wall 32.In the typical construction of a blower housing outer wall 32 such asthat shown in FIG. 1, this expansion angle is constant for all pointsalong the volute outer wall 32 in the rotation direction, resulting in agradually increasing distance between the outer circumference of the fanwheel 28 and the outer wall 32 as the outer wall extends in the rotationdirection around the fan wheel.

The air distribution blower 26 of the typical high efficiency furnacerepresented in FIG. 1 has been found to be disadvantaged in that theflow of air directed from the blower is primarily concentrated on onlysmall portions of the secondary heat exchanger 24 and the primary heatexchanger 22. The air flow directed from the blower through the portionsof the heat exchangers is represented by the arrows 34 shown in FIG. 1.As seen in FIG. 1, the scroll configuration of the volute outer wall 32and the close positioning of the fan wheel 28 to the interior surface ofthe outer wall 32 primarily concentrates the flow of air through thereduced areas of the secondary heat exchanger 24 and the primary heatexchanger 22 shown to the left in FIG. 1. This reduces the efficiency ofheat transfer from the heat exchangers to the air flow. Theconcentration of the air flow to reduced areas of the secondary 24 andthe primary 22 heat exchanger also results in a significant pressuredrop. This additional pressure drop requires additional blowerhorsepower, i.e. a larger blower motor. The requirement for a largerblower motor decreases the electrical efficiency of the furnace. Also,the heat generated by operating a larger motor would especially detractfrom the cooling system efficiency when an air conditioning heatexchanger is added at the air outlet opening 18 in the enclosure 12. Ifthe problem of the concentration of air flow through the reduced areasof the heat exchangers is attempted to be overcome by simply enlargingthe size of the exhaust outlet of the conventional blower housing, theresulting scroll shape of the blower housing would not be able toadequately convert the velocity head of the air flow through the housinginto static pressure of the resulting blower system and the overallblower system would not be successful in saving energy.

The original equipment manufacturers (OEM) of heating, ventilating andair conditioning (HVAC) systems look to pair their high efficiencyfurnace with a high efficiency air conditioner. The OEM's desire forhigh seasonal energy efficiency ratio (SEER) ratings has resulted invery tall evaporator coils being used in furnace/air handler enclosures.However, the enclosures must still be able to fit inside the 8 footvertical space of a typical residential basement. Therefore, with morevertical space in the furnace/air handler enclosure being occupied bythe taller air conditioning evaporator coils to achieve a high SEERrating, OEM's have turned to using low profile blower housings having areduced vertical height dimension in their furnace/air handlerenclosures.

The typical high efficiency furnace employing a primary heat exchangerand a secondary heat exchanger creates a large pressure drop for the lowprofile blower to move air through the furnace. The increased pressuredrop requires a larger impeller fan for power and pressure, however, thefan must still fit inside the low profile blower. This has caused OEM'sto attempt to make what is called a “tight” blower where a largeimpeller blower is placed in a low profile blower housing. The use ofthe large impeller results in plenty of flow and pressure, but withoutgood results for efficiency. Some OEM's have attempted to make lowprofile blowers that have a small exhaust opening. However, thisdetracted from the efficiency of the blower especially when used in ahigh efficiency furnace having both primary and secondary heatexchangers. Other OEM's have tried to make blower housings with largeexhaust openings, but these over-expanded the flow of air exiting thehousing.

SUMMARY OF THE INVENTION

The present invention overcomes the efficiency problems associated withthe constructions of prior art 90+ furnace blowers by providing a blowerwith a unique housing design that spreads out the distribution air flowover the secondary heat exchanger to a larger extent than the existingblowers of the prior art. This enables the blower to operate with lessof a pressure drop through the heat exchangers than that of prior artblowers. The scroll design of the blower housing also efficiently turnsthe velocity head of the air flow through the housing to usable staticair pressure. In addition, it has been found through testing that theblower housing design of the invention applied to a low profile 80+furnace blower has a similar or superior static efficiency to that of aregular profile blower. In a similar manner to the 90+ furnace, in an80+ furnace where the primary heat exchanger is located close to theblower housing air outlet opening, the enlarged air outlet opening ofthe blower housing of the invention directs air over a larger area ofthe primary heat exchanger than blower housings of the prior art, andthereby creates energy savings. This enables the design of the blowerhousing to be employed in low profile 80+ furnaces to provide anefficiency gain, even though there is no secondary heat exchanger in thelow profile furnace. The improved efficiency of the blower housingenables a reduction in the exterior dimensions of the furnace enclosurein which the blower housing is used.

In the typical construction of an air distribution blower, the pressureloss is proportional to the air flow velocity squared through a givenrestriction of the blower housing. Just a 15 percent increase in a twodimensional rectangular plane that represents the effective flow areaacross the secondary heat exchanger of the furnace can potentiallycreate a (1.15×1.15=1.3225), (1/1.3225=0.756) 25% increase in efficiencydue to air pressure loss at the secondary heat exchanger.

With this in mind, the high efficiency furnace of the present inventionemploys a blower housing with an enlarged air outlet opening, while theexterior dimensions of the blower housing remain substantially the sameas those of the prior art blower housing used in a high efficiencyfurnace.

The blower housing of the present invention employs a fan wheel withforward curved impeller blades for low noise and for reducing the sizeof the fan wheel. Fan wheels with forward curved impeller blades areknown to create large amounts of pressure and air flow for a relativelysmall size of fan wheel.

To obtain a large air outlet opening in the blower housing withoutincreasing the exterior dimensions of the blower housing, the presentinvention utilizes an exponentially increasing expansion angle along thelength of the blower housing volute-shaped outer wall. Alternatively,the blower housing of the invention utilizes an exponentially increasingexpansion angle along a substantial portion of, or substantial portionsof the outer wall. Where the expansion angle of the volute outer wall ofprior art blower housings increases at a constant rate, the expansionangle of the volute outer wall of the blower housing of the presentinvention increases exponentially as the outer wall extends around thefan wheel in the rotation direction of the fan wheel. The exponentiallyincreasing expansion angle of the volute outer wall provides a verylarge air outlet opening while still having a volute shape around theentire length of the blower housing outer wall following the outer wallcutoff.

In a preferred embodiment, the expansion angle of the last quarter ofthe volute-shaped outer wall length, from 270° to 360° of thevolute-shaped length increase at an exponential rate in a range of 1.7to 2.4. This exponent range of 1.7 to 2.4 has proved to be critical tothe operation of the low profile high efficiency blower housing of theinvention. The expansion angle increasing at a smaller exponential ratethan the preferred range does not create the desired coriollis componentto pull the air flow through the impeller or the required scroll housingvolume in low profile housings. The expansion angle increasing at alarger exponential rate than the preferred range will concentrateexcessive air flow through a small portion of the impeller and theoverall expanded blower housing will not smoothly convert the air flowvelocity head in the blower housing to static pressure. All of theseattributes are important for a high efficiency blower housing'soperation.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features of the invention are set forth in the followingdetailed description of the invention and in the drawing figures.

FIG. 1 is a partial view of the construction of a prior art highefficiency furnace.

FIG. 2 is a partial view of the high efficiency furnace of FIG. 1employing the unique blower housing of the present invention.

FIG. 3 is a front perspective view of the opposite side of the blowerhousing in FIG. 2, removed from the furnace enclosure.

FIG. 4 is an additional front perspective view of the blower housing.

FIG. 5 is a rear perspective view of the blower housing.

FIG. 6 is a side elevation view of the blower housing.

FIG. 7 is a side elevation view of the opposite side of the blowerhousing shown in FIG. 6.

FIG. 8 is a front elevation view of the blower housing.

FIG. 9 is a schematic representation of the dimensional relationshipsbetween the circumference of the fan wheel and the volute-shaped outerwall of the blower housing of the invention.

FIG. 10 is a partial view of a low profile 80+ furnace employing theblower housing of the invention.

FIGS. 11 and 12 are graphs comparing the operation of blower housings ofthe invention with those of the prior art.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 2 is a perspective, cut away view of the high efficiency furnace ofthe invention that employs the blower housing of the invention having anenlarged air outlet opening and an exponentially increasing expansionangle. The furnace of the invention is primarily constructed in the samemanner as known high efficiency furnaces. The difference in the furnaceof the invention is in the unique design of the blower housing of thefurnace. This unique design of the blower housing provides a superiordistribution of air flow through the secondary and primary heatexchangers of the furnace, and thereby reduces the horsepower requiredby the distribution blower motor enabling an increase in the efficiencyof the high efficiency furnace. Because much of the construction of thefurnace shown in FIG. 2 is the same as that of FIG. 1, the samecomponent parts of the furnace of FIG. 2 will be described onlygenerally and are identified by the same reference numbers used inidentifying the component parts in FIG. 1, but with the referencenumbers being followed by a prime (′).

The high efficiency furnace 10′ of the present invention also includesan external housing enclosure 12′ that contains the interior volume 14′of the furnace. Only a rear wall 12R and a left side wall 12LS of thefurnace enclosure 12′ are entirely shown in FIG. 2. The front wall 12Fand right side 12RS wall are shown with portions removed to provide aview of the interior components of the furnace. It should be understoodthat the front and rear walls have the same width and height dimensionsand the left side and right side walls have the same width and heightdimensions whereby the enclosure has the exterior configuration of arectangular cube. The front wall 12F of the furnace enclosure or thebottom of the furnace enclosure is provided with an air inlet openingthat allows ambient air of the residence in which the furnace is used toenter into the enclosure interior 14′. The air inlet opening is oftencommunicated with a cold air return duct system of the residence. Airthat is heated by the furnace 10′ is discharged to an air distributionconduit system of the residence (not shown) through a distribution airoutlet opening 18′. The distribution air outlet opening 18′ ispositioned at the top of the enclosure shown in FIG. 2.

The primary heat exchanger 22′ is positioned at the top of the enclosureinterior volume 14′ adjacent the distribution air outlet opening 18′.The secondary heat exchanger 24′ is positioned just below the primaryheat exchanger 22′. The use of both a primary heat exchanger and asecondary heat exchanger qualifies the furnace of the invention as ahigh efficiency furnace, or a 90+ AFUE furnace.

The blower 38 of the invention is positioned in the enclosure interior14′ at the same position as the prior art blower 26, i.e., just belowthe secondary heat exchanger 24′. The fan wheel has an axis of rotation44 that defines mutually perpendicular axial and radial directionsrelative to the blower 38. As shown in FIG. 2, the fan wheel rotates ina clockwise rotation direction when the fan is operating. Rotation ofthe fan wheel 42 draws ambient air into the blower 38 as represented bythe arrow labeled (AIR FLOW) in FIG. 2. In the preferred embodiment, thefan wheel 42 is comprised of a plurality of forward curved fan blades46. The forward curved fan blades 46 of the fan wheel 42 reduce thenoise of operation of the fan wheel 42. Furthermore, the air flow movingthrough the fan wheel 42 is concentrated in the last half of the scrollshaped outer wall of the blower housing, and especially in the last 90degrees of the scroll shaped outer wall where the expansion angle of theouter wall exceeds 10 degrees. This creates a higher velocity of airflow through the forward curved fan blades 46, which increases thestatic pressure gained on the fan wheel 42 due to the coriollis effect.The higher air flow velocity also increases the velocity head of the airflow off of the forward curved blades 46. This effect reduces the sizeof the fan wheel required for an equal powered blower, and increases theefficiency of the blower due to the greater pressure being generated onthe fan wheel blades.

The apparent way to increase the exhaust area size of the blower housingair outlet opening is to increase the expansion angle of the blowerhousing outer wall. However, the prior art practice has been to designblower housings with a constant expansion angle. Some prior art blowerhousings have used increasing expansion angles, but the manner in whichthe blower housing's expansion angles were increased did not achieve thedesired effect due to either the rate of increasing the expansion anglebeing inadequate, or the rate of increasing the expansion angle beingtoo large and thus missing the desired effect. Additionally, increasingthe expansion angle of the blower housing outer wall creates anextremely large blower housing that does not fit adequately in the lowprofile furnace enclosure. The resultant additional size of the furnaceenclosure needed to house a blower housing having an increased expansionangle creates a negative aspect for the consumer, i.e., the furnaceenclosure requires more space in the consumer residence. Additionally,the manufacturer of the furnace must add cost to make the largerenclosure to accommodate the blower housing. Thus, merely increasing theexhaust area of the air outlet opening of a blower housing by increasingthe expansion angle of the blower housing outer wall is not a viableoption.

FIG. 2 shows one side of the blower housing 48 of the invention. FIG. 3shows the opposite side of the blower housing 48, with the blowerhousing having been removed from the high efficiency furnace enclosure12′. The opposite first 52 and second 54 side walls of the blowerhousing are constructed in the typical manner as prior art blowerhousings and are basically flat, parallel side walls positioned ataxially opposite ends of the fan wheel 42. An air inlet opening isprovided in the first side wall 52, and an opening that accommodates themotor that rotates the fan wheel 42 is provided in the second side wall54. The side walls of the blower housing of the invention are basicallythe same as those of the prior art.

To obtain a large exhaust area of the blower housing air outlet opening,the blower housing 48 of the present invention utilizes an exponentiallyincreasing expansion angle in the design of the blower housing voluteouter wall 56. FIG. 2 shows the blower housing 48 positioned in the highefficiency furnace 10′, with the first side wall being removed to showthe position of the fan wheel 42 in the interior of the blower housing48 and the relative positioning of the blower housing 48 in the furnace10′. As shown in FIG. 2, the novel configuration of the blower housingouter wall 56 creates an enlarged air outlet opening 58 of the blowerhousing. This enlarged air outlet opening 58 directs distribution airover a larger area of the secondary heat exchanger 24′ and the primaryheat exchanger 22′ than blower housings of the prior art such as thatshown in FIG. 1. This greater amount of distribution air is representedby the arrows 62 in FIG. 2. The enlarged air outlet opening 58 spreadsthe flow of air out over the furnace heat exchanger and thereby reducesthe pressure loss across the furnace. This lowers the required pressurethat the blower must generate, and enables the use of a more efficientmotor to operate the blower.

Furthermore, the blower housing of the invention does a superior job ofpulling the air flow through the forward curved impeller blades, alongwith converting the air flow velocity through the housing scroll tousable static pressure. Although the blower housing of the invention hasspecial benefits with respect to its use in furnaces by reducing thepressure through those furnaces, the blower housing of the inventionalso has superior efficiency as a blower housing used in an air handlerwhere high efficiency is desired.

As stated earlier, the larger air distribution outlet opening 58 isachieved by employing an exponentially increasing expansion angle in thedesign of the volute-shaped outer wall 56 of the blower housing, asopposed to the constant increasing expansion angle employed in thedesign of prior art blower housings. The enlarged air outlet opening 58is also achieved with the overall blower housing width dimension, thelength dimension and the depth dimension of the blower housing 48 beingthe same as that of prior art blower housings. The improved efficiencyof the blower housing enables a reduction in the exterior dimensions ofthe furnace enclosure in which the blower housing is used.

With the exponentially increasing expansion angle of the outer wall 56of the blower housing, as the blower housing volute outer wall 56extends around the blower housing in the rotation direction of the fanwheel, the scroll volume aggressively becomes larger in the interior ofthe housing. This is especially true as the outer wall 56 approaches theair outlet opening 58. This increase in the interior volume enablesexhaust velocities of air flow to be reduced, and creates a blowerhousing where a greater portion of the air flow velocity head isconverted to static pressure. This increases efficiency because the airflow velocity head energy would have been lost outside of the scrollinterior. This further increases the overall efficiency of the blowerhousing.

FIG. 9 is a schematic representation of a side view of the blowerhousing volute outer wall 56 and the fan wheel 42 in the blower housing.The description of the blower housing 48 and the fan wheel 44 to followis only one exemplary embodiment of the blower 38 of the invention. Inother environments the construction of the blower housing and fan wheelmay vary. However, as will be explained, the construction and the designof the blower housing outer wall 56 is based on an exponentiallyincreasing expansion angle, where many prior art blower housings havebeen designed with a constant increasing expansion angle. Theexponentially increasing expansion angle can be utilized along theentire volute-shaped length of the outer wall, or along only a portionof the volute-shaped length of the outer wall, or along separateportions of the volute-shaped length of the outer wall. Furthermore, theconstruction of the volute outer wall radially opposite any point on thecircumference of the fan wheel is proportional to the circumferentialdimension of the fan wheel at that point, raised to an exponentialvalue.

The blower housing outer wall 56 has a volute-shaped portion thatdefines a majority of the length of the outer wall. The volute-shapedportion of the outer wall 56 could also be described as having a scrollconfiguration or a spiral configuration. These general configurationsare common to blower housings of the prior art. However, the novelconfiguration of the blower housing outer wall 56 of the invention isdefined as having an exponentially increasing expansion angle as thevolute-shaped wall 56 extends in the rotation direction around the fanwheel axis of rotation 44. As viewed in FIG. 9, the outer wall includesa cut-off portion 72. The outer wall also includes a straight portion 74at the enlarged air outlet opening 58. The straight portion 74 of theouter wall has no expansion angle and extends in a straight line. Thevolute-shaped outer wall 56 is the length of the outer wall that extendsfrom the cutoff 72 to the straight portion 74.

FIG. 9 illustrates the dimensional relationship between a portion of thecircumference of the fan wheel 42 and the volute-shaped length of theouter wall 56 of the invention positioned radially opposite the portionof the fan wheel. The fan wheel 42 shown in FIG. 9 has a diameterdimension D and circumference C dimension. In the low profile, highefficiency embodiment of the blower assembly, the fan diameter dimensionD is 11.87 inches. In the explanation of the construction of the blowerhousing outer wall 56 to follow, the dimensions of the outer wall arebased on circumferential dimensions of the fan wheel circumference.These circumferential dimensions of the fan wheel begin at point (b) onthe fan wheel shown in FIG. 9. The dimensions are measured around in acounter-clockwise rotation direction as shown in FIG. 9 to an endingpoint on the fan wheel that coincides with the point (o). A line drawnfrom the fan wheel axis of rotation 44 through the fan wheel beginningpoint (a) marks a zero degree reference point on the circumference ofthe fan wheel.

Beginning from the fan wheel beginning point (a) at the zero degreecircumference of the fan wheel, and extending around the fan wheelcircumference in the counter-clockwise direction of rotation of the fanwheel shown in FIG. 9, a second point (b) is positioned on the fan wheel68 degrees from the first point (a). Point (b) is the beginning of thefan wheel circumferential dimensions that are used in determining thedimensions of the outer wall 56. A third point (c) is positioned on thefan wheel 90 degrees from the first point (a). Point (c) is also 22degrees (or 0.061π D) from point (b). A fourth point (d) is positionedon the fan wheel 112.5 degrees from the first point (a). Point (d) isalso 44.5 degrees (or 0.124π D) from point (b). A fifth point (e) ispositioned on the fan wheel 135 degrees from the first point (a). Point(e) is also 67 degrees (or 0.186π D) from point (b). A sixth point (f)is positioned on the fan wheel 157.5 degrees from the first point (a).Point (f) is also 89.5 degrees (or 0.249π D) from point (b). A seventhpoint (g) is positioned on the fan wheel 180 degrees from the firstpoint (a). Point (g) is also 112 degrees (or 0.311π D) from point (b).An eighth point (h) is positioned on the fan wheel 202.5 degrees fromthe first point (a). Point (h) is also 134.5 degrees (or 0.374π D) frompoint (b). A ninth point (i) is positioned on the fan wheel 225 degreesfrom the first point (a). Point (i) is also 157 degrees (or 0.436π D)from point (b). A tenth point (j) is positioned on the fan wheel 247.5degrees from the first point (a). Point (j) is also 179.5 degrees (or0.499π D) from point (b). An eleventh point (k) is positioned on the fanwheel 270 degrees from the first point (a). Point (k) is also 202degrees (or 0.561π D) from point (b). A twelfth point (l) is positionedon the fan wheel 292.5 degrees from the first point (a). Point (I) isalso 224.5 degrees (or 0.624π D) from point (b). A thirteenth point (m)is positioned on the fan wheel 315 from the first point (a). Point (m)is also 247 degrees (or 0.686π D) from point (b). A fourteenth point (n)is positioned on the fan wheel 337.5 degrees from the first point (a).Point (n) is also 269.5 degrees (or 0.749π D) from point (b). Afifteenth point (o) is positioned on the fan wheel 360 degrees from thefirst point (a) and coincides with the first point. Point (o) is also292 degrees (or 0.811π D) from point (b). These multiple points on thefan wheel are radially aligned with points on the blower housing outerwall 56. The circumferential distances of the fan wheel points (b-o)from the point (b) on the fan wheel are employed in calculating thedistance of the blower housing outer wall 56 from the circumference ofthe fan wheel 44 at each of the radially aligned points on the blowerhousing outer wall. In this way the exponentially increasing expansionangle of the blower housing of the invention is determined.

The beginning of the volute or scroll shaped portion of the outer walllength 56 begins just past the cut-off portion 72 in the direction ofrotation of the fan wheel 44. The beginning end of the volute-shapedportion begins at a point (B) on the outer wall 56. Point (B) isradially aligned with the 68 degree point (b) on the circumference ofthe fan wheel 44. From this beginning point (B) on the volute-shapedportion on the outer wall length 56, the outer wall length has points(C, D, E, F, G, H, I, J, K, L, M, N, O) that are radially spacedoutwardly from and correspond to the respective circumferentially spacedpoints (c, d, e, f, g, h, i, j, k, l, m, n, o) on the circumference onthe fan wheel 42. The volute-shaped portion of the outer wall length 56has an ending point (O) that is radially aligned with the zero degreefan wheel beginning point (a) and the 360 degree fan wheel ending point(o). The volute-shaped portion of the outer wall length 56 also has afirst section and a second section. The first section extends from point(B) to its end at point (K) at 270 degrees, and the second sectionextends from point (K) to its end at point (O) at 360 degrees.

The radial spacing between the points on the fan wheel circumference andtheir radially aligned corresponding points on the volute-shaped portionof the outer wall 56 is determined by the equation: Y=A+B x^(c)

In the above equation, the “x” value is the circumferential distance onthe fan wheel circumference at which the radial spacing between the fanwheel and the volute-shaped length of the outer wall is beingcalculated. This value is raised to the exponential power of (c). It hasbeen determined empirically that the value (c) for points on thecircumference of the fan wheel 42 from the 68 degree fan wheel point (b)to the 270 degree fan wheel point (k) is an exponent in the range of 1.3to 1.7. In the example, the exponent is 1.5. For points on thecircumference of the fan wheel from the 270 degree fan wheel point (k)to the fan wheel point corresponding to 360 degrees (o), the value ofthe exponent “c” is in the range of 1.7 to 2.4. In the example, theexponent is 2.1.

In an illustrative example of the above-referenced equation, the “A”factor is a minimum height factor for the blower housing 48. In theexample that follows, the minimum height factor “A” is 0.550 inches. Thefactor “B” in the above equation is a factor picked by the furnacedesigner to create as large of an exhaust opening as is practical, alongwith keeping the blower housing within size restrictions of the furnaceenclosure 12′. The furnace designer designs the blower housing to allowa reasonable flow of air around the blower housing in the enclosure 12′,while trying to hold down the exponential expansion of the blowerhousing outer wall 56 as much as possible, while at the same timeobtaining the primary objective of a large air outlet opening 58. In theexample that follows, the factor “B” is 0.02288 for points on thecircumference of the fan wheel 42 from the 68 degree fan wheel point (b)to the 270 degree fan wheel point (k), and is 0.003735 for the points onthe circumference of the fan wheel from the 270 degree point (k) to the360 degree fan wheel point (o).

The following is a table setting forth the circumferential points on thecircumference of the fan wheel 42 and the corresponding radial distance(Y) to the radially aligned point on the volute-shaped length 56 of theblower housing outer wall calculated using the equation Y=A+B x^(c).

Y = A + Bx^(c) D = 11.87″ A = 0.550″ Fan wheel A Y circumference (X)(inches) B C (inches)  1 a, A 0° reference  2 b, B at 68° x is 0 π D.550 .02288 1.5 .550  3 c, C at 90° x is 0.061 π D .550 .02288 1.5 .564 4 d, D at 112.5° x is 0.124 π D .550 .02288 1.5 .626  5 e, E at 135° xis 0.186 π D .550 .02288 1.5 .742  6 f, F at 157° x is 0.249 π D .550.02288 1.5 .914  7 g, G at 180° x is 0.311 π D .550 .02288 1.5 1.145  8h, H at 202.5° x is 0.374 π D .550 .02288 1.5 1.435  9 i, I at 225° x is0.436 π D .550 .02288 1.5 1.787 10 j, J at 247.5° x is 0.499 π D .550.02288 1.5 2.199 11 k, K at 270° x is 0.561 π D .550 .02288 1.5 2.675 12l, L at 292.5° x is 0.624 π D .550 0.003735 2.1 3.214 13 m, M at 315° xis 0.686 π D .550 0.003735 2.1 3.817 14 n, N at 337.5° x is 0.749 π D.550 0.003735 2.1 4.485 15 o, O at 360° x is 0.811 π D .550 0.003735 2.15.218

The above table sets forth the exponentially increasing expansion angleof the volute-shaped outer wall 56 of the invention based on a fan wheel42 having a diameter dimension D of 11.87 inches. It can be seen thatthe size of the fan wheel influences the circumferential dimensionsmeasured at the fan wheel points (b, c, d, e, f, g, h, i, j, k, l, m, n,o) which are raised to an exponential value to obtain the radial spacingbetween each of the respective points on the circumference of the fanwheel 42 and a radially aligned point on the volute outer wall 56. Ablower housing having a volute outer wall 56 designed according to theearlier set forth equation and as illustrated in the above tableprovides an enlarged air outlet opening 58 without significantlyincreasing the overall dimensions of the blower housing 48 from that ofprior art blower housings.

In alternate embodiments, the expansion angle could increaseexponentially with there being a single exponent value along asubstantial portion of the volute-shaped outer wall length 56, but notthe entire length. Additionally, the expansion angle could increaseexponentially along separate portions of the volute-shaped outer walllength, with there being different exponent values for the separateportions of the volute-shaped outer wall length.

In the alternate embodiments of the invention, in the last 90° of thevolute-shaped side wall length from point (K) to point (0) or from 270°to 360° on the volute-shaped length of the outer wall, the expansionangle increasing at an exponential rate in a range of 1.7 to 2.4 enablesthe exhaust velocities of the air flow to be reduced, and creates ablower housing where a greater proportion of the air flow velocity headis converted to static pressure. This increases the efficiency of theblower housing because this velocity head energy would have been lostoutside of the blower housing. This further increases the overallefficiency of the system. Too large of an expansion angle outside of thedesired range would over-expand the blower housing and the area of airflow through the housing resulting in the air flow velocity headconversion to static pressure being too little and ineffective, failingto provide the effect needed.

In further embodiments of the invention, the blower housing of theinvention could be employed in a low profile furnace, specifically an80+ AFUE furnace, as well as in other types of furnaces and airhandlers, and also in AC units. The alternate embodiment of a 80+furnace is illustrated in FIG. 10. FIG. 10 illustrates the earlierdescribed blower housing 48 of the invention employed in a low profilefurnace 82, where the low profile furnace employs only a primary heatexchanger 84 and does not include a secondary heat exchanger asdescribed earlier. Used in this environment, the blower housing 48 ofthe invention has similar or superior static efficiency to that of aregular profile blower. The use of the blower housing 48 in a lowprofile furnace allows savings in shipping costs and sheet metal cost.The particular two stage exponential growth of the volute outer wall 56of the blower housing 48 provides similar performance and efficiency tothe low profile 80+ furnace as that of a regular profile blower in a lowprofile size. In a similar manner to the 90+ furnace, in the 80+ furnace82 where the primary heat exchanger 84 is located close to the blowerhousing air outlet opening, the enlarged air outlet opening of theblower housing of the invention directs air over a larger area of theheat exchanger 84 than blower housings of the prior art, and therebycreates energy savings.

In addition to being employed in a 90+ furnace and an 80+ furnace, theblower housing 48 of the invention may be employed in an air handler.Air handlers (abbreviated AHU) are employed in HVAC systems to move airthrough the systems. A typical air handler comprises a metal enclosurecontaining the blower housing of the invention. The air handlerenclosure is typically communicated with one or more other enclosurescontaining heating and/or cooling coils and air filters. The air handlertypically communicates with duct work that distributes the conditionedair through a building and returns the air to the air handler. Airhandlers are also used to distribute air and return air directly to andfrom the area being served by the air handler without duct work. In thetypical operation of an air handler, the rotation of the fan in theblower housing of the invention would pull air through the air filterand the heating and/or cooling coils to the blower housing and thendistribute the conditioned air from the blower housing.

Although the above equation and the above described method of designingthe volute-shaped outer wall of a blower housing based on thecircumference dimensions of the fan wheel are described with referenceto a particular fan wheel diameter dimension, there are particularblower housing and fan wheel dimension relationships that provide thesynergistic effect of the increased efficiency of the blower housing ofthe invention. In the blower housing of the invention these synergisticresults are achieved when the ratio of the minimum radial dimension ofthe air outlet opening (for example, the minimum dimension between thecutoff 72 at point (B) and the end of the straight portion 74 of theblower housing outer wall 48 opposite the point (O) shown in FIG. 9),and the fan wheel outer diameter dimension is at least 0.67. Inaddition, the ratio of the distance dimension between the fan wheel axisof rotation 44 and the end of the first section of the blower housingouter wall volute-shaped length at point (K), and the fan wheel outerdiameter dimension is at most 0.77. This ratio is critical to obtainingthe optimum efficiency from using a large impeller fan in a low profileblower housing. Furthermore, in the preferred embodiment the radialdistance between the fan wheel axis of rotation 44 and the volute-shapedlength of the blower housing outer wall increases as the volute-shapedlength extends from a first end of the volute-shaped length around thefan wheel to the second end of the volute-shaped length. Preferably theincrease is exponential.

The dimensional relationships between the fan wheel and the blowerhousing outer wall of the invention set forth above result in thesynergistic increase in the efficiency of the blower housing of theinvention. This synergistic increase in efficiency is the result ofthree basic principles.

(1) The enlarged air outlet opening of the blower housing spreads outthe flow of air exiting the blower housing over the furnace heatexchanger to a greater extent than prior art blower housings, andthereby reduces the pressure loss across the furnace. This lowers therequired pressure that the blower must generate.

(2) The flow of air moving through the fan wheel is concentrated in thelast half of the scroll configuration of the blower housing, andespecially in the last 90° of the scroll configuration from point (K) topoint (0) or from 270° to 360° on the volute-shaped length of the outerwall. Here the outer wall increases at an expansion angle of 10° orgreater. This creates a higher air flow velocity through theforward-curved blades of the fan wheel, which increases static pressuregained on the fan wheel due to the coriollis effect. The higher air flowvelocity also increases the velocity head off of the forwarded-curvedblades of the fan wheel for greater power.

(3) The blower housing volume aggressively becomes larger in thedirection of fan wheel rotation in the blower housing of the invention,especially toward the air outlet opening. This enables the exhaustvelocities of the air flow to be reduced, and creates a blower housingwhere a greater portion of the air flow velocity head is converted tostatic pressure. This increases the efficiency of the blower housingbecause this velocity head energy would have been lost outside of theblower housing. This further increases the overall efficiency of thesystem.

FIG. 11 is a graph illustrating the gain in efficiency of a highefficiency 90+ furnace employing the blower housing of the invention ascompared to high efficiency 90+ furnaces of the prior art. In FIG. 11,the bottommost line on the graph represents the operation of the blowerhousing of the invention in a 90+ furnace. The other graph linerepresents the operation of 90+ furnaces of the prior art. From thisgraph it can be seen that the blower housing of the invention requiresless watts of the fan wheel motor to move a volume of air through thefurnace than the blower housings of the prior art.

FIG. 12 is a graph similar to that of FIG. 11, but showing a comparisonof the low profile 80+ blower housing of the invention compared with alow profile blower housing of the prior art. In FIG. 12, the lower lineon the graph represents the operation of the low profile blower housingof the invention. In this graph it can also be seen that the low profileblower housing of the invention requires less electrical watts to move avolume of air as compared to a blower housing of the prior art.

The above described embodiments of the invention were chosen in order tobest explain the principles of the invention and its practicalapplication to thereby enable others skilled in the art to best utilizethe invention in various embodiments and with various modifications asare suited to the particular use contemplated.

As various modifications could be made in the constructions hereindescribed and illustrated without departing from the scope of theinvention, it is intended that all matter contained in the foregoingdescription or shown in the accompanying drawings shall be interpretedas illustrative rather than limiting. Thus, the breadth and scope of thepresent invention should not be limited by any of the above-describedexemplary embodiments, but should be defined only in accordance with thefollowing claims appended hereto and their equivalents.

1. An air handler comprising: an enclosure having an interior volume anda distribution air outlet opening on the enclosure that is adapted forcommunication with an air distribution system; a fan wheel in theenclosure interior volume, the fan wheel having an outer diameterdimension and a circumference dimension, the fan wheel having a centeraxis of rotation that defines mutually perpendicular axial and radialdirections and the fan wheel being rotatable about the center axis ofrotation in a rotation direction; a blower housing in the enclosureinterior volume, the blower housing containing the fan wheel and havingan air outlet opening, the air outlet opening having a minimum radialdimension, a ratio of the minimum radial dimension and the fan wheelouter diameter dimension being at least 0.67, the blower housing havingan outer wall with a volute-shaped portion that extends from a first endof the volute-shaped portion around the fan wheel in the rotationdirection to the second end of the volute-shaped portion, and thevolute-shaped portion of the blower housing outer wall having first andsecond sections as the volute-shaped portion extends in the rotationdirection around the fan wheel, where an expansion angle of the secondsection of the volute-shaped portion increases at an exponential rate of1.7 to 2.4.
 2. The air handler of claim 1, further comprising: the firstsection of the volute-shaped portion subtending an angle of at most 202°at the fan wheel center axis.
 3. The air handler of claim 1, furthercomprising: the first section of the volute-shaped portion subtending anangle of 202° at the fan wheel center axis and the second section of thevolute-shaped portion subtending an angle of 90° at the fan wheel centeraxis.
 4. The air handler of claim 1, further comprising: an expansionangle of the first section of the volute-shaped portion increases at anexponential rate of 1.3 to 1.7.
 5. The air handler of claim 1, furthercomprising: the air handler being a furnace.
 6. The air handler of claim1, further comprising: the volute-shaped portion of the outer wallconsisting essentially of the first section and the second section ofthe volute-shaped portion.
 7. The air handler of claim 1, furthercomprising: a ratio of a radial distance between the fan wheel axis andan end of the first section of the outer wall volute-shaped portion, andthe fan wheel outer diameter dimension being at most 0.77.
 8. An airhandler comprising: an enclosure having an interior volume and adistribution air outlet opening on the enclosure that is adapted forcommunication with an air distribution system; a fan wheel in theenclosure interior volume, the fan wheel having an outer diameterdimension and a circumference dimension, the fan wheel having a centeraxis of rotation that defines mutually perpendicular axial and radialdirections and the fan wheel being rotatable about the center axis ofrotation in a rotation direction; a blower housing in the enclosureinterior volume, the blower housing containing the fan wheel and havingan air outlet opening, the air outlet opening having a minimum radialdimension, a ratio of the minimum radial dimension and the fan wheelouter diameter dimension being at least 0.67, the blower housing havingan outer wall with a volute-shaped portion that extends from a first endof the volute-shaped portion around the fan wheel in the rotationdirection to the second end of the volute-shaped portion, the first endof the volute-shaped portion being spaced radially a first distancedimension from the fan wheel axis of rotation and the second end of thevolute-shaped portion being spaced radially a second distance dimensionfrom the fan wheel axis of rotation that is larger than the firstdistance, and the volute-shaped portion of the blower housing outer wallhaving first and second sections with different generally increasingexpansion angles as the volute-shaped portion extends in the rotationdirection around the fan wheel, where the expansion angle of the secondsection of the volute-shaped portion increases at an exponential rate of1.7 to 2.4.
 9. The air handler of claim 8, further comprising: the firstsection of the volute-shaped portion extends over at most 202° of thefan wheel circumference dimension.
 10. The air handler of claim 8,further comprising: the first section of the volute-shaped portionextends over 202° of the fan wheel circumference dimension and thesecond section of the volute-shaped portion extends over 90° of the fanwheel circumference dimension.
 11. The air handler of claim 8, furthercomprising: the first section of the blower housing volute-shapedportion extends from the first end of the volute-shaped portion aroundthe fan wheel in the rotation direction to an end of the first sectionof the volute-shaped portion, the end of the first section of thevolute-shaped portion being spaced radially a first distance dimensionfrom the fan wheel axis of rotation; and, a ratio of the first distancedimension and the fan wheel outer diameter dimension being at most 0.77.12. The air handler of claim 8, further comprising: the air handlerbeing a furnace.
 13. The air handler of claim 8, further comprising: thevolute-shaped portion of the outer wall consisting essentially of thefirst section and the second section of the volute-shaped portion. 14.An air handler comprising: an enclosure having an interior volumeenclosed in opposite front and rear walls of the enclosure each having awidth dimension, opposite left and right side walls of the enclosureeach having a length dimension, and an opposite top and bottom of theenclosure, and a distribution air outlet opening on the enclosure thatis adapted for communication of a distribution air stream from theenclosure to an exterior environment of the enclosure; a fan wheel inthe enclosure interior volume, the fan wheel having an outer diameterdimension, an axis of rotation that defines mutually perpendicular axialand radial directions, and the fan wheel being rotatable in a rotationdirection around the axis of rotation; a blower housing in the enclosureinterior volume, the blower housing having an interior volume containingthe fan wheel and an air flow outlet opening, the air outlet openinghaving a minimum radial dimension, a ratio of the minimum radialdimension and the fan wheel outer diameter dimension being at least0.67, the blower housing having first and second side walls on axiallyopposite ends of the fan wheel, and the blower housing having an outerwall having a width dimension extending between the first and secondside walls, the outer wall having a volute-shaped portion that spiralsaway from the fan wheel axis of rotation as it extends in the rotationdirection from a first end of the volute-shaped portion at one side ofthe air flow outlet opening around the blower housing interior volume toa second end of the volute-shaped portion at an opposite side of the airflow outlet opening from the first end, the volute-shaped portion of theblower housing outer wall having first and second sections, the secondsection being spaced from the first end of the volute-shaped portion bythe first section, and the second section of the volute-shaped portionhaving an expansion angle that increases at an exponential rate in arange of 1.7 to 2.4.
 15. The air handler of claim 14, furthercomprising: the first section of the volute-shaped portion subtending anangle of at most 202° at the fan wheel center axis.
 16. The air handlerof claim 14, further comprising: the first section of the volute-shapedportion subtending an angle of 202° at the fan wheel center axis and thesecond section of the volute-shaped portion subtending an angle of 90°at the fan wheel center axis.
 17. The air handler of claim 14, furthercomprising: an expansion angle of the first section of the volute-shapedportion increases at an exponential rate of 1.3 to 1.7.
 18. The airhandler of claim 14, further comprising: the air handler being afurnace.
 19. The air handler of claim 14, further comprising: thevolute-shaped portion of the outer wall consisting essentially of thefirst section and the second section of the volute-shaped portion. 20.The air handler of claim 14, further comprising: the outer wall having astraight portion that extends from the second end of the volute-shapedportion to the air flow outlet opening of the blower housing.
 21. Theair handler of claim 14, further comprising: a ratio of a radialdistance between the fan wheel axis and an end of the first section ofthe outer wall volute-shaped portion, and the fan wheel outer diameterdimension being at most 0.77.
 22. An air handler comprising: anenclosure having an interior volume and a distribution air outletopening on the enclosure that is adapted for communication with an airdistribution system; a fan wheel in the enclosure interior volume, thefan wheel having an outer diameter dimension and a circumferencedimension, the fan wheel having a center axis of rotation that definesmutually perpendicular axial and radial directions and the fan wheelbeing rotatable about the center axis of rotation in a rotationdirection; a blower housing in the enclosure interior volume, the blowerhousing containing the fan wheel and having an air outlet opening, theblower housing having an outer wall with a volute-shaped portion thatextends from a first end of the volute-shaped portion around the fanwheel in the rotation direction to the second end of the volute-shapedportion, and the volute-shaped portion of the blower housing outer wallhaving first and second sections as the volute-shaped portion extends inthe rotation direction around the fan wheel, where the first section ofthe volute-shaped portion has a positive expansion angle and anexpansion angle of the second section of the volute-shaped portionincreases at an exponential rate of 1.7 to 2.4.
 23. The air handler ofclaim 22, further comprising: the first section of the volute-shapedportion subtending an angle of at most 202° at the fan wheel centeraxis.
 24. The air handler of claim 22, further comprising: the firstsection of the volute-shaped portion subtending an angle of 202° at thefan wheel center axis and the second section of the volute-shapedportion subtending an angle of 90° at the fan wheel center axis.
 25. Theair handler of claim 22, further comprising: an expansion angle of thefirst section of the volute-shaped portion increases at an exponentialrate of 1.3 to 1.7.
 26. The air handler of claim 22, further comprising:the air handler being a furnace.
 27. The air handler of claim 22,further comprising: the volute-shaped portion of the outer wallconsisting essentially of the first section and the second section ofthe volute-shaped portion.
 28. The air handler of claim 22, furthercomprising: the air outlet opening having a minimum radial dimension anda ratio of the minimum radial dimension and the fan wheel outer diameterdimension being at least 0.67.
 29. The air handler of claim 22, furthercomprising: a ratio of a radial distance between the fan wheel axis andan end of the first section of the outer wall volute-shaped portion, andthe fan wheel outer diameter dimension being at most 0.77.